JP3088643B2 - Non-breathable surface material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-breathable surface material, particularly a surface material suitable for an automobile interior material.

[0002]

2. Description of the Related Art Conventionally, as an automobile interior material, a laminate is used, in which a nonwoven fabric or a knitted fabric backed with a cushion material is used as a skin material, and this is joined to a base material with a non-breathable hot melt film.

For example, Japanese Patent Application Laid-Open No. 64-69684 discloses a hot-melt adhesive film in which a high-melting-point polyolefin resin is used as a non-ventilating layer and a low-melting-point polyamide polymer is laminated on both sides of the hot-melt adhesive film. Discloses a non-breathable automobile interior material used in the above. Non-breathable hot-melt films having the same basic structure and automobile interior materials using the same are also disclosed in JP-A-7-60883, JP-A-7-68721, JP-A-7-117571, and the like. It has been disclosed.

However, the conventional non-breathable hot-melt film is thin when it is supplied to the market, and when used, the film is wrapped and wound, so that the film is twisted or overlapped, and handling is inconvenient. there were. In particular, when manufacturing a material for a ceiling of an automobile, a construction area is large, and a decrease in yield due to generation of defective products has been a problem. All of these also fuse the skin material and the non-breathable hot melt film by heat fusion, and as a result, in interior materials in which the cushioning material is backed on the back surface of the skin material, often a small depression (Called pock)) and spoiled the aesthetics.

Japanese Unexamined Patent Publication No. 3-39241 discloses a two-layer surface material obtained by laminating a nonwoven fabric surface containing a thermoplastic resin and a polyolefin film. A skin material such as a tricot and a cushion made of a soft urethane foam or the like are disclosed. It does not use wood.

[0006]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a non-breathable surface material in a form which is easy to manufacture in the manufacture of automotive interior materials, and a non-breathable interior material having a structure in which it is difficult to form a pock on its surface. It is intended to provide a surface material.

[0007]

The present invention comprises a skin material (1), a cushioning material (2) and a non-breathable hot melt film layer (3) in this order, and a non-breathable material having each layer adhered. The present invention relates to a surface material, wherein at least a cushion material and a non-breathable hot melt film layer are bonded by a frame lamination method. Further, the present invention is a non-breathable hot-melt film layer is a multilayer film layer including at least a hot-melt resin layer and a non-breathable layer constituting at least one of the outermost layers, wherein the hot-melt resin layer is a skin material It relates to the non-breathable surface material described above, which is integrated to be located on the opposite side.

FIG. 1 is a schematic sectional view of a non-breathable surface material of the present invention, wherein (1) shows a skin material, (2) shows a cushion material, and (3) shows a non-breathable hot melt film layer.

As the skin material, there are nonwoven fabrics generally used as interior materials, for example, nonwoven fabrics such as polyester fiber and polypropylene fiber; woven fabric, knit, brushed knit and the like.

[0010] The thickness of the skin material is 1 to 3 mm. The cushion material used in the present invention is a flexible polyurethane foam,
Any material can be used as long as it can be bonded to the air-impermeable film by a method such as frame lamination, dry lamination, or hot melt lamination.

The density is preferably 0.016 to 0.050 g / m ³ , more preferably 0.020 to 0.035 g / cm ³ . The thickness of the cushion material is 1 to 10 mm, more preferably 2 to 5 m
m. If the thickness is less than 1 mm, it is difficult to join by frame lamination or the like. If the thickness is more than 10 mm, lateral ventilation is generated and the skin material is easily stained. When the thickness of the cushion material is small, the softness of the interior material is lost, and the interior material becomes flat.

The air-impermeable hot melt film layer of the present invention
(3) can take various laminated structures, but the basic structure is as shown in FIG.
(6) (this is simply called an outer layer), a layer composed of a non-breathable film (4) and a substrate side hot melt film I (5) (this is simply called an inner layer) or an inner layer as shown in FIG. (5) and a non-breathable film (4). Of course, the non-breathable hot melt film layer of the present application
(3) is not limited to this as described later.

The resin for the non-breathable film (4) used in the present invention has a melting point of 130 ° C. or higher, preferably a melting point of 130 to 25.
A thermoplastic resin film or a non-melting film at 0 ° C, more preferably 140 to 230 ° C, and a resin having a melting point higher than the molding temperature by about 20 ° C or more is preferable. In particular, a resin that can be fused with a foamed flexible polyurethane frame laminate is preferable.

Specific examples of the resin vary depending on the type of the resin used for the inner layer and the outer layer, but include cellulose resins such as high melting polyamide resin, high melting polyolefin resin, polyester resin, polyurethane resin, polyvinyl alcohol resin, cellophane, etc. An acrylic resin, a polycarbonate resin and the like are exemplified.

Examples of the high melting point polyamide resin include nylon 6/66, 6, 610, 12, and 11; examples of the high melting point polyolefin include a polypropylene resin and an ethylene-vinyl alcohol resin.

The non-breathable film (4) is used for blocking air permeability between the base material and the skin material and for preventing contamination of the skin material surface due to ventilation. It is desirable that no damage or pinholes be formed. Therefore, the thickness is 5 μm or more, more preferably 1 μm or more.
0-30 μm is suitable. When the thickness is 30 μm or more, the elongation becomes poor, and the stretchability of the drawn portion becomes poor during thermal fusion with the substrate.

The hot melt film I (5) is used for fusing the air-impermeable film layer (4) to a base material for interior (not shown). Therefore, the melting temperature of the hot melt resin is 70
C. to 150.degree. C., particularly preferably about 80 to 130.degree. In particular, when a material that is subjected to low-temperature thermocompression bonding such as a cardboard or resin board is used as the base material, it is preferable to use a resin having a lower temperature, for example, a melting point of 70 to 130 ° C. In the case of such a low-temperature thermocompression bonding, in order to lower the melt viscosity of the hot melt resin at the time of compression bonding and to ensure sufficient fusion bonding to a cardboard or a resin board, M is required.
If I is too small, it is inappropriate.

The preferred MI is from 5 to 100, more preferably from 6 to 50. The thickness of the hot melt film I (5) is 10 to 50 μm, more preferably 20 to 40 μm. Resins suitable for the hot melt film I (5) are a polyolefin resin, a low melting polyamide resin, a polyester resin, a thermoplastic polyurethane resin and the like. Polyolefin resins are cost-effective.

Examples of the polyolefin resin include polyethylene, for example, low-density polyethylene, medium-density polyethylene, high-density polyethylene, linear low-density polyethylene, branched low-density polyethylene, and the like, polypropylene, modified polypropylene, 1-butene, 2-butene, Isobutene,
1,3-butadiene and the like; olefin monomer copolymer,
Copolymers with other monomers having a polymerizable double bond such as styrene and vinyl chloride; ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, ethylene-methyl acrylate copolymer, ethylene-butyl Acrylate copolymer, ethylene-methyl methacrylate copolymer, ethylene-ethyl methacrylate copolymer,
Ethylene-butyl methacrylate copolymer, ethylene-
Examples thereof include (meth) acrylic acid copolymers, ethylene-maleic acid copolymers, ethylene-itaconic acid copolymers, and modified resins such as acid modifications thereof.

These polyolefins may be used as a mixture of two or more. Other additives such as a viscosity modifier, a tackifier, and an antioxidant may be added. Homopolymers of olefins, for example, polyethylene alone, have poor fusion properties with substrates such as cardboard, resin boards or thermoformable polyurethane when used alone, so other polyethylene resins such as ethylene-vinyl acetate copolymer resins, ethylene-
It is preferable to use an ethyl acrylate copolymer resin, an ethylene-methyl acrylate copolymer resin, an ethylene- (meth) acrylic acid copolymer resin, an ethylene-maleic acid copolymer resin, an acid-modified olefin resin or the like in combination.

As polyamides, nylon 6/66 /
12, nylon 6/610/12, nylon 6/66 /
610/12, nylon 6/66/11/12 and the like. From the viewpoint of adhesiveness, it is preferable to use an aminocarboxylic acid containing ω-aminoundecanoic acid as a raw material as a monomer component.

When the substrate is a cardboard or resin board, a particularly preferred resin for the hot melt film I is a modified polyethylene resin such as an acid-modified resin of a polyolefin.

In the non-breathable surface material of the present invention, a hot-melt film II (6) may be further provided on the side opposite to the hot-melt film I (5) via a non-breathable layer. This hot melt film II is a non-breathable hot melt film layer
It can also act as an adhesive for bonding (3) to the cushioning material (2). As the resin for the hot melt film II (6), the same resin as the resin for the hot melt film I (5) can be used. The same resin may be used for the same surface material, or another resin may be used. A particularly preferred resin is polyamide when the cushioning material is a foamed flexible polyurethane. The melting temperature of the resin for the hot melt film II is 80 to 150 ° C, particularly 90 to 130 ° C.
Is preferred. MI is 5 or more, preferably 5 to 10
0, more preferably 6 to 50. Two or more resins may be used in combination. The thickness of the hot melt film II (6) is 10 to 50 μm, more preferably 20 to 40 μm.

The non-breathable hot-melt film of the present invention has a structure in which another resin layer is provided between the non-breathable film (4) and the hot melt film I or II in addition to the above two-layer or three-layer structure. It may be a multilayer structure having more than two layers. Such a resin layer is mainly used as an adhesive layer for bonding the layers (4) and (5) or (6), or as an intermediate layer for adapting when the fusion property between the two is insufficient, or It is used to exhibit various functions such as a layer for adjusting the fluidity by melting together with the hot melt layer (5) or (6).

In the present invention, the method for producing the air-impermeable hot melt film layer (3) is not particularly limited, and any method generally used for producing a conventional laminated film, such as a coextrusion method, an extrusion lamination method, and a dry lamination method, is used. The method is not particularly limited.

The total thickness of the non-breathable hot-melt film layer (3) is 15 to 80 μm in a two-layer structure, more preferably 3 to 80 μm.
The thickness is preferably adjusted to 0 to 60 μm, 25 to 130 μm for a three-layer configuration, and more preferably 50 to 100 μm. In the present invention, the surface material has a cushion material (2) such as foamed flexible polyurethane on the back side of the skin material (1). Conventionally, the cushion material and the air-impermeable resin layer (4) have been fused through a hot melt film, but it has been found that this often causes the skin material to pock. In the present invention, without interposing the hot melt film II (6), the non-breathable film is bonded to the foamed flexible polyurethane layer by frame lamination, dry lamination, hot melt lamination, or the like, and the pock is eliminated. Is also good.

The skin material of the present invention is fused with a base material to produce an automobile interior material. At that time, the surface material has an appropriate thickness and the workability is good.

As the substrate of the present invention, those used as conventional substrates for automobile interiors may be appropriately used. Examples of such a base material include a nonwoven fabric in which inorganic fibers, organic fibers or a mixed fiber thereof are bonded to each other with a thermoplastic resin, or a molded article of an organic fiber or an inorganic fiber impregnated with a thermosetting resin. There are a substrate, cardboard and the like in which a glass fiber layer or the like is bonded to both sides of a resin foam such as a board or urethane. The fiber density is 300-700g
/ M ² , and in the case of a nonwoven fabric, needle punching may be performed as necessary to increase the strength. After the step of heat-forming (shaping) a cardboard, a resin board and the like by a hot press, it is thermocompression-bonded to a skin material in the next step. Usually, a hot press is used for the thermocompression bonding, and the temperature is set to 110 to 130 so as not to damage the skin material.
Heat fusion at low temperature of ℃. As described above, when the thermocompression bonding temperature is low, if the MI of the hot melt film is small, the melt viscosity increases, and the hot melt film does not penetrate into the base material, so that a sufficient fusion temperature cannot be obtained. Therefore, when such a material is used, it is preferable to use a resin having high fluidity at a low temperature, particularly MI5 or more, as the hot melt film (5).

The fusion of the surface material of the present invention and the substrate may be carried out according to a conventional method. For example, the hot-melt film I (5) side of the surface material and the substrate are overlapped, heated to a temperature equal to or higher than the melting point of the hot-melt film I, melted, and pressed at the same time. Press mold temperature 110 to 140 ° C Clearance 0.3 to 1.5 mm Time 10 to 60 seconds is appropriate.

Hereinafter, the present invention will be described with reference to examples.

EXAMPLE 1 Three air-impermeable hot-melt layers shown in FIG.
(3) was produced by co-extrusion (T-die method). Hot melt film I (5): Copolyamide 6/610/12 Melting point 105 ° C, MI12, thickness 30 µm Non-breathable film (4): Copolymer nylon 6/66 Hot melt film II (6): Maleic anhydride Modified ethylene-ethyl acrylate copolymer resin, melting point: 104 ° C, MI: 6.0, thickness: 30 μm, total thickness: 75 μm, Tricot of polyester fiber (150 g / m ² etc.) as skin material (1), cushion material (2) Foamed flexible polyurethane (Material density 0.023 g / cm ³ thickness 3 mm
2) was manufactured by fusing a non-breathable surface material having the structure shown in FIG. The obtained non-breathable surface material is used as a resin board base material.
(Thickness: 3 mm), the film I (5) was overlaid so as to be in contact with the substrate, and pressed by hot pressing to obtain an interior material. The thermocompression bonding conditions are upper mold 120 ° C, lower mold 160 ° C, and clearance 0.
5 mm, time 30 seconds. The thickness of the obtained interior material was 6 mm.

Example 2 As a hot melt film I (5), a maleic anhydride-modified ethylene-ethyl acrylate copolymer resin, melting point 95
Example 1 except using a temperature of 8.0 ° C., an MI of 8.0 and a thickness of 30 μm.
In the same manner as in the above, a three-layer non-breathable hot melt film (3) having a thickness of 75 μm was produced. A non-permeable surface material and an interior material were obtained in the same manner as in Example 1 except that the obtained three-layer film (3) was used.

Example 3 A non-breathable hot melt film having the following structure shown in FIG.
(3) was produced by co-extrusion inflation molding. Non-breathable film (4): Copolymer nylon 6/66, melting point 200 ° C., thickness 15 μm Hot melt film (5): Maleic anhydride-modified ethylene-ethyl acrylate copolymer resin, melting point 95 ° C., MI 8.0, thickness 30 μm Overall thickness: 45 μm The resulting air-impermeable film (4) of the obtained two-layer air-impermeable hot melt film (3) is placed on the cushion material (2) side, and the air-impermeable surface material and the interior are the same as in Example 1. And wood.

Example 4 The non-breathable surface material and the interior material obtained in Examples 1 to 3 were subjected to a peeling test, a heat-resistant creep test and a pinhole test. Table 1 shows the results.

(1) Peeling test The specimen was cut into a 25 mm width, and the adhesive strength was measured with an Instron type tensile tester. Non-breathable surface material (between cushion material (2) / non-breathable hot melt film layer (3)), T peeling, 23 ° C, tensile speed 200 mm / min, interior material (between cushion material (2) and base material) : 180 ° peeling
23 ° C., tensile speed 200 mm / min (2) Pinhole test Hot melt film surface of non-breathable surface material (5) Cushion material (2) of interior material and non-breathable hot melt layer
(3) Spray a commercially available pinhole detection liquid (Microcheck, manufactured by Nippon Kozai Co., Ltd.) on the non-breathable film surface (4) and hot melt film II surface (6) where the space has been peeled off and leave for 1 minute The post solution was wiped off, and the presence or absence of pinholes was examined. (3) Heat-resistant creep test The interior material was cut to a width of 25 mm, the skin material with a cushion layer was peeled off from the base material, opened at 180 °, and 10 skin materials were applied.
With a load of 0 g, left in an atmosphere of 85 ° C. for 24 hours,
The degree of peeling was examined. Table 1 shows the above results.

[0035]

[Table 1]

[0036]

The skin material of the present invention has an appropriate thickness,
It is extremely easy to handle compared to conventional non-breathable multilayer hot-melt films, has excellent ventilation barrier properties, has good heat-sealing properties to various substrates, and is suitable for industrial production of interior materials for automobiles ing.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view of a non-breathable surface material.

FIG. 2 is a schematic sectional view of a non-breathable surface material.

[Explanation of symbols]

 (1) Skin material (2) Cushion material (3) Non-breathable hot melt film layer (4) Non-breathable film (5) Hot melt film I (6) Hot melt film II

──────────────────────────────────────────────────続 き Continuation of front page (58) Field surveyed (Int.Cl. ⁷ , DB name) B60R 13/02 B32B 1/00-35/00

Claims (3)

(57) [Claims] 1. A surface material used for an automobile interior material obtained by adhering a surface material and a base material, comprising a skin material (1), a cushion material (2) made of foamed soft urethane, and a non-breathable hot melt film layer. A non-breathable surface material having (3) in this order, wherein each layer is bonded, wherein at least a cushion material and a non-breathable hot melt film layer are bonded by a frame lamination method. . 2. A non-breathable hot-melt film layer is a multilayer film layer including at least a hot-melt resin layer constituting at least one of an outermost layer and a non-breathable layer, wherein the hot-melt resin layer is opposite to a skin material. The air-impermeable surface material according to claim 1, wherein the surface material is integrated so as to be located on a surface of the non-permeable surface. 3. The non-breathable hot-melt film layer is a multilayer film layer including at least a hot-melt resin layer constituting both outermost layers and a non-breathable layer.
Non-breathable surface material according to 1.